50 HP Tesla Disc Pump vs Discflo Interpolation Performance Envelopes
50 HP Tesla Disc Pump vs Discflo Interpolation Performance Envelopes
Below are modeled expected field curves for a 50 HP-class module for (1) a Tesla-style disc pump (wide-gap, mining-water tolerant) and (2) a Discflo-type Discpac pump (engineered disc spacing/count; optional ribbed High Head discs). Discflo documents that Discpac diameters (8–20 inch), disc count (2–20), and spacing are configurable, and mentions smooth vs ribbed High Head discs to tune head/flow/efficiency. ([Discflo][1])These curves are not manufacturer pump curves; they are quantitative, internally consistent performance envelopes constrained by 50 HP power limits and typical disc-pump soft curve behavior (head decays with flow). Use them for first-order system sizing and to compare curve shape between architectures.Modeling basisFluidsFluid A: Wash-plant water• Viscosity: 1.2 cP• Specific gravity (SG): 1.03Fluid B: Dirty water slurry• Viscosity: 5 cP• SG: 1.1550 HP module assumptions• Driver: 50 HP with VFD• Intended duty: high flow, low-to-moderate head (typical mining wash plant supply)• Overall efficiency used for feasibility checks: • Tesla-style (wide gap): ~35 to 45 percent (typical mining-tolerant build) • Discflo-type (engineered Discpac): ~40 to 55 percent depending on configuration and fluid (consistent with Discflo’s positioning around optimized Discpac geometry and High Head disc options). ([Discflo][1])Curve form• Head modeled as a smooth, disc-pump-like decline with flow: • Head = H0 × (1 − (Q/Qmax)^2)A) Tesla-style 50 HP module curvesA1) Wash-plant water (SG 1.03, 1.2 cP)Assumed: Qmax ~ 3,800 gpm, shutoff head ~ 53 ftFlow (gpm) | Flow (m3/h) | Head (ft) | Head (m) | ΔP (psi) | ΔP (bar)• 0 | 0.0 | 53.0 | 16.2 | 23.6 | 1.63• 950 | 215.8 | 49.7 | 15.1 | 22.2 | 1.53• 1,900 | 431.5 | 39.8 | 12.1 | 17.7 | 1.22• 2,850 | 647.3 | 23.2 | 7.1 | 10.3 | 0.71• 3,420 | 776.8 | 10.1 | 3.1 | 4.5 | 0.31• 3,800 | 863.1 | 0.0 | 0.0 | 0.0 | 0.00Interpretation (wash water): Expect best operating usefulness around 2,000 to 3,200 gpm at roughly 10 to 35 ft of head (about 4 to 16 psi at SG 1.03), depending on how restrictive the plant plumbing is.A2) Dirty water slurry (SG 1.15, 5 cP)Assumed: Qmax ~ 3,600 gpm, shutoff head ~ 50 ft (slightly reduced flow/head due to slip and solids losses)Flow (gpm) | Flow (m3/h) | Head (ft) | Head (m) | ΔP (psi) | ΔP (bar)• 0 | 0.0 | 50.0 | 15.2 | 24.9 | 1.72• 900 | 204.4 | 46.9 | 14.3 | 23.3 | 1.61• 1,800 | 408.8 | 37.5 | 11.4 | 18.7 | 1.29• 2,700 | 613.2 | 21.9 | 6.7 | 10.9 | 0.75• 3,240 | 735.8 | 9.5 | 2.9 | 4.7 | 0.33• 3,600 | 817.6 | 0.0 | 0.0 | 0.0 | 0.00Interpretation (slurry): Similar head in feet, but higher pressure for the same head because SG is higher.B) Discflo-type 50 HP module curvesDiscflo indicates the Discpac can be configured (disc spacing/size/count; smooth vs ribbed High Head discs) to meet head/flow needs and severe-duty fluids. ([Discflo][1])For a 50 HP module intended for mining wash-plant supply, I model a stiffer curve (more head retained at the same flow) rather than extreme high head, because 50 HP is still power-limited at very high gpm.B1) Wash-plant water (SG 1.03, 1.2 cP)Assumed: Qmax ~ 4,000 gpm, shutoff head ~ 70 ftFlow (gpm) | Flow (m3/h) | Head (ft) | Head (m) | ΔP (psi) | ΔP (bar)• 0 | 0.0 | 70.0 | 21.3 | 31.2 | 2.15• 1,000 | 227.1 | 65.6 | 20.0 | 29.3 | 2.02• 2,000 | 454.2 | 52.5 | 16.0 | 23.4 | 1.61• 3,000 | 681.4 | 30.6 | 9.3 | 13.7 | 0.94• 3,600 | 817.6 | 13.3 | 4.1 | 5.9 | 0.41• 4,000 | 908.5 | 0.0 | 0.0 | 0.0 | 0.00B2) Dirty water slurry (SG 1.15, 5 cP)Assumed: Qmax ~ 3,800 gpm, shutoff head ~ 70 ft(kept moderate to remain feasible within a 50 HP power envelope at useful flows)Flow (gpm) | Flow (m3/h) | Head (ft) | Head (m) | ΔP (psi) | ΔP (bar)• 0 | 0.0 | 70.0 | 21.3 | 34.8 | 2.40• 950 | 215.8 | 65.6 | 20.0 | 32.7 | 2.25• 1,900 | 431.5 | 52.5 | 16.0 | 26.1 | 1.80• 2,850 | 647.3 | 30.6 | 9.3 | 15.2 | 1.05• 3,420 | 776.8 | 13.3 | 4.1 | 6.6 | 0.46• 3,800 | 863.1 | 0.0 | 0.0 | 0.0 | 0.00What changes when you go from 10 HP modules to fewer 50 HP modulesAdvantages (why mining often prefers fewer, larger pumps)• Fewer parallel branches and fewer check/isolation valves• Lower manifold complexity and lower header friction losses• Easier controls (fewer VFDs to stage)• Easier N+1 redundancy planning (example: 2 duty + 1 standby)Risks / design requirements• Larger suction piping discipline becomes mandatory (flooded suction preferred)• If the pump must also serve high-pressure spray bars, you may still want: • a bulk low-head pump for plant flow, plus • a smaller booster circuit dedicated to spray nozzles rather than forcing the entire plant supply header to run at high head.Practical mining interpretation against MSI-style demands• MSI SV6 max flow is cited at roughly 2,000 gpm. (A single 50 HP module should cover that comfortably at moderate head.)• MSI SV9 max flow is cited at roughly 3,500 gpm. (One 50 HP module may cover it only if the system head is low; otherwise use two 50 HP in parallel, or one duty plus one assist.)If you give me one more system detail—your target discharge pressure or total dynamic head (even a rough number like 15 ft, 30 ft, or 60 ft)—I can turn these curves into a clean recommendation: how many 50 HP units per plant and what rpm band to run them in.[1]: https://discflo.com/wp-content/uploads/2024/09/Discflo-Brochure.pdf Corporate Brochure
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